carbon fiber technology facility - energy

Dave Warren, PI Lee McGetrick, Presenter Director, Carbon Fiber Technology Facility Oak Ridge National Laboratory

May 15, 2013 Project ID # LM003

Status as of April 5, 2013

Carbon Fiber Technology Facility

This presentation does not contain any proprietary, confidential, or otherwise restricted information

2 Managed by UT-Battelle for the U.S. Department of Energy

Carbon Fiber Technology Facility (CFTF) ARRA Capital Project Overview

• Funds received FY10Q2

• CD-2/3 FY11Q2

• Project completed (CD-4) FY13Q2

• Six months ahead of schedule, under budget

• Cost of Carbon Fiber

• Technology scaling

• Market development

• $34.7M Budget – Capital project

Timeline

Budget

Barriers addressed

Partners and Collaborators*

• Harper, International

• Hills, Inc.

• Engineering Services Group

• Roane State Community College

(all are U.S. companies)

* Capital MIE project only


The nation needs a scale-up facility for low-cost carbon fiber technology demonstration

“DOE does not…possess the advanced carbon fiber research, development, and demonstration capability necessary to achieve

its mission goals...need to develop a multi-industry, multi-

participant technology demonstration and deployment

facility that can be easily accessed by researchers and

stakeholders for key industries.”

75 Stakeholders from government and industry attended a workshop at ORNL in March 2009

Relevance


CFTF will enable introduction of large scale low-cost carbon fibers (LCCF) into U.S. markets • Structural carbon fiber has a variety of light-weighting

applications – Defense: Heat shields, aircraft wings and fuselages, lightweight

weaponry – Automotive: 10% mass reduction equates to 6-7% increase in fuel

economy – Wind energy: 100 m wind turbine blades for off-shore – mass = k

(length)^3

• Nonstructural carbon fiber – Single thermal insulation application requires 500 tons of fiber per

year – Additional application for graphite electrodes

would require 500 tons of fiber per year – Filtration – Adsorption

Relevance


Potential automotive market alone is huge for low-cost carbon fiber Carbon fiber potential in 2017 at 50% of current price

Source: Lucintel, ACMA Composites 2012 ~ 3X current global CF demand for ALL APPLICATIONS

Relevance


The CFTF has three primary missions

Demonstrate low-cost carbon fiber

(LCCF) technology scalability

Produce quantities of LCCF for large-scale material and

process evaluations and prototyping

Partner with educational

institutions to develop a skilled

workforce

CFTF is the bridge from R&D to deployment and commercialization Relevance


CFTF is the world’s most capable open-access carbon fiber manufacturing facility

• Alternative precursor materials

• Multi-component structural fiber extrusion technologies

• Alternative conversion technologies

• New surface treatment and sizing technologies

• Product development using LCCF

The CFTF serves as a national asset to assist industry in overcoming the barriers of carbon fiber cost, technology

scaling, and product and market development Approach


Project Deployment Phases Design &

Fabrication Installation Site

Acceptance Testing

Commissioning Operations

Specifications Preliminary Design (30/60) Final Design (90+) FAT’s

Staffing Procedures Development Training

Detailed Test Plans Start OJT for Shift Managers and Technicians

Supplier provided classroom and OJT Commence 3-shift operations Supplier on-site throughout

Fiber production using PAN precursor “Dial in” and gain proficiency Planning for alternative precursors HAZOP reviews

- Suppliers - Project

Team - SME’s - DOE

HAZOP corrective

actions verification by

operations team

Independent

Start-up Review

Transition to Operations

Plan

Critical Decision 4

(CD-4)

(3/11 – 6/12) (6/12 – 10/12) (10/12 – 11/12) (12/1 – 2/13) (3/13)

Approach


Capital project was completed 6 months ahead of schedule and $2.5M under budget • Executed project per DOE Order 413.3B

– Met or exceeded all project Key Performance Parameters

• Utilized streamlined small business contracting mechanisms to accelerate installation

• Built strong start-up and commissioning team – Key personnel recruited with

relevant experience – Adequate training time was built into

schedule

• Cultivated excellent relationships with suppliers and potential industry partners

Accomplishments


The CFTF was officially dedicated on March 26, 2013

Ribbon cutting (l to r): Council on Competitiveness President & CEO Deborah Wince-Smith, Congressman Chuck Fleishmann, DOW executive Florian Schattenmann , Governor Bill Haslam, ORNL Director Thom Mason, Assistant Secretary for EERE David Danielson, and Ford executive Jim DeVries.

Gary Lownsdale, Chief Technology Officer , Plasan Carbon Composites introducing the new Corvette hood to VIP guests

Dr. David Danielson announcing the Clean Energy Manufacturing

Initiative Elizabeth Wayman, Director for the Clean Energy Initiative hosted a panel session exploring resources and opportunities in clean energy manufacturing

Dr. Danielson hosted a round-table event to discuss details of the Clean Energy Manufacturing Initiative


Key accomplishment: Carbon fiber exceeding target properties achieved at first production attempt using PAN as baseline

Lot Summary for Lot Number PW241130230 – Commissioning Run 1 with 24K Tow

Take-up Fiber Diameter Tensile Tensile Modulus Elongation Tensile Tensile Modulus ElongationPosition (microns) Strength Young's Modulus Strain at Break Strength Chord Modulus (0.1 - 0.6%) Strain at Break

(Ksi) (Msi) (%) (Ksi) (Msi) (%)

2 7.75 450.2 30.349 1.396 387.4 31.161 2.62610 8.29 402.2 29.407 1.330 351.2 30.708 1.76822 8.43 470.4 29.083 1.562 373.8 30.263 2.210

1 8.04 475.2 30.965 1.497 368.0 33.392 1.41212 7.49 512.7 30.273 1.596 374.7 32.035 1.67914 7.80 448.8 31.546 1.376 348.7 32.166 1.417

Avg. = 7.97 459.9 30.271 1.460 367.3 31.621 1.852SD = 0.35 36.5 0.924 0.108 14.9 1.140 0.479

Count = 6 6 6 6 6 6 6

Single Filament Test Method Full Tow Test Method

PAN precursor on Creel Oxidation Oxidized PAN ready for carbonization

Target Properties: 250 ksi tensile, 25 Msi modulus, 1% elongation to break


• Established Technician Internship program

• Developed Technician training system to be used a national asset to support industry growth

• Developed modern media-based real-time work control system – Patent filing in process

Key accomplishment: Linked with local community college for highly successful workforce development

Chemistry & Mathematics

Mechanical Skills Safety Aspects Process Controls

“Black Art” HAZARDS:

• Correct process upsets

• Prevent excursions

• Equipment adjustments

• In-process maintenance

• Chemical

• Thermal

• Mechanical

• Electrical

• Environment

• Alarm response

• Controls logic

• Process adjustments

• Pressure & flow balancing

• Splicing

• Tow repairs


Key accomplishment: Project safety and compliance – zero injuries or events

Significant safety hazards and controls implemented


ORNL resource contributions without direct project expense

Electrical Safety • Mark Matthews Fire Protection • Harvey Goranson

Physical Security • John Watkins • Brent Holden

IT/Cyber Security • Jess Wales • Dave Wantland • Eddie Bishop Emergency Management • Rick Rodreguez

Facilities Development • Jack Stellern • Randy Pickens • Mark Turner • Don Sokel • Jane Holly • Chris Tavino • Wayne Smathers Equipment Design • Cliff Eberle • Bob Norris • Felix Paulauskas Real Estate/Lease/ Building Maintenance • Doug Rose • Ellen Reeves Legal • Andrea Reagan

Energy & Environmental Sciences • Suzy Fowler (DOM) • David Fowler Health & Safety (Overall) • Kris Thomasson • David Fowler Environmental & Waste Management • Jim Eaton • Don Naab OSHA • Andrew Bush

Quality • Judah Wilkins Training • Allen White • Sharon Byrd

Collaboration


ORNL is formally collaborating with over 40 companies on LCCF technology and commercialization

• 3M Company • ABC Group Sales &

Engineering • Advanced Composites Group • Alpha Industries • ATK Launch Systems • BASF Corporation • Chomarat NA, LLC • Composite Applications Group • Continental Structural Plastics • Cytec Carbon Fibers • Dow Chemical Company • Despatch Industries • Faurecia • Fibria • Ford Motor Company • General Electric • Global Composites Solutions • Graftech International • Hanwha Azdel • Harper International • Hills, Inc.

• Innovation Valley Inc. • Innventia • INOAC USA • Lignol Innovations • Materials & Chemistry Laboratory • Metalsa Structural Products • NFT, Inc. • NovusFolium • Plasan Carbon Composites • Sabic Innovative Plastics • SGL Carbon Fibers • Sodra Innovation • SSOE Group • Steelcase • Swift Engineering • Toho Tenax America • United Technologies Research

Center • United States Enrichment Corp.

(USEC) • Virdia, Inc. • Volkswagen Group of America Collaboration


• Dow and Ford team up to bring low-cost, high-volume carbon fiber composites to next-generation vehicles – Reducing weight of new cars and

trucks by up to 750 lbs by the end of the decade

– Foundational work at ORNL on low-cost precursors key to automotive applications

– DOE and state of Michigan fund $13.5M research agreement to develop lower cost carbon fiber production process using polyolefin in place of conventional polyacrylonitrile (PAN) as feedstock

– Novel process could reduce production cost by 20%

– High-volume commercial launch anticipated outcome

First competitively awarded project to buy time at CFTF

Collaboration


Potential Partnerships under discussion • Harper, International, with expressed interest in bringing existing and

future clients to run trials at the CFTF

• GrafTech™, in development lignin-based carbon fiber for high insulation applications. A DOE proposal has been submitted to support the full scale commercialization of this material.

• Kaltex Group, a North American company a major producer of textile-grade polyacrylonitrile fibers.

• Domtar, who recently announced a large investment supported by DOE and USDA in its Plymouth, NC plant to produce 75 tons per day of a new clean lignin (“BioChoice”). Domtar is working closely with ORNL to explore the conversion of this material into lignin-based carbon fiber.

• Plasan Carbon Composites, who has an R&D Center located at ORNL's Science and Technology Park, and is working on several projects with ORNL, including one project funded by DOE. Plasan was recently been awarded a large contract to produce parts for the 2014 Corvette.

• Composites Application Group, with space in the Oak Ridge Science and Technology Park and an active project in carbon fiber utilizing fiber from the Carbon Fiber Technology Facility

Collaboration


Summary • Relevance

– The CFTF is the bridge from R&D to large-scale commercialization of low-cost carbon fiber in U.S.

• Approach – Dr. David Danielson, March 26, 2013: "My staff has called

this project a text book example of perfect execution and have told me that they have never seen a project run so well."

• Technical Accomplishments and Progress – Project completed 6 months ahead of schedule and $2.5M

under budget – Carbon fiber with good properties produced on first try

• Collaborations/Partnerships – Capital project phase: Harper, Hills, ESG Construction – Future: Numerous opportunities being deliberately pursued

carbon fiber technology facility - energy

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